Applied Energy 74 (2003) 369–381

www.elsevier.com/locate/apenergy

Co-firing of biomass in coal-fired utility boilers

Kati Savolainen*
Enprima Engineering Oy, PL 61, Vantaa 01601, Finland

Abstract
Co-firing tests with sawdust and coal have been carried out at FORTUM’s Naantali-3 CHP
power plant (315 MWfuel). The Naantali-3 plant is a tangentially-fired pulverised-coal unit
with a Sulzer once-through boiler that produces 79 MW electricity, 124 MW district heat and
70 MW steam. Naantali-3 is equipped with roller coal mills (Loesche), modern low-NOx-
burners (IVO RI-JET), over-fire air (OFA), electrostatic precipitator (ESP) and flue-gas
desulphurization plant (FGD). Coal and sawdust were blended in the coal yard, and the
mixture fed into the boiler through coal mills. Tests were carried out for three months during
the April 1999 to April 2000 period with pine sawdust (50-65% moisture as received). During
the tests, sawdust proportions of 2.5–8% (from the fuel input) were examined. The co-firing
tests were successful in many ways, but the behaviour of the coal mills caused some problems,
and therefore the simultaneous feed will not be the solution in a long-term use. Fortum has
developed a new concept for co-firing coal and biofuels in large pulverised-coal fired boilers.
The experiences gained from the Naantali co-firing tests and a good knowledge of low-NOx
burning and combustion behaviour of different fuels at Fortum, was used when the new co-firing
concept was developed. This concept consists of a separate biofuel grinding system and bio- or
bio-coal-burners. By using this system, it is possible to utilize many kinds of biofuels in PC-boilers
as well as increase the share of biofuels, compared to the simultaneous feed of biofuel and coal.
# 2003 Published by Elsevier Science Ltd.
Keywords: Co-firing, biomass; Coal; Tangentially-fired boiler; Low-NOx burners; Fuel feeding system

1. Introduction

CO2 is considered to be a greenhouse gas of significance. Improving the efficiency

of the existing power-plants using fossil fuels, the use of renewable fuels and renewable

Abbreviations: OFA, overfire air; ESP, electrostatic precipitator; FGD, flue-gas desulphurization
plant; PC, pulverised fired-coal; DIMAC; UBC; SD.
* Fax: +358-10-453 3410.
E-mail address: [email protected] (K. Savolainen).

0306-2619/03/$ - see front matter # 2003 Published by Elsevier Science Ltd.

doi:10.1016/S0306-2619(02)00193-9
370 K. Savolainen / Applied Energy 74 (2003) 369–381

energy sources (e.g. solar, wind) and the increased use of nuclear power are all con-
sidered to be important means of reducing greenhouse-gas emissions. One possibility
to reduce greenhouse-gas emissions is to substitute biomass for coal in pulverised
coal-fired (PC) units. The use of biomass in PC boilers also offers advantages asso-
ciated with emissions other than reducing greenhouse-gas emissions. Substituting
biomass for coal reduces SO2 emissions, and a reduction in NOx emissions is also
possible. These are due to the low sulfur and low nitrogen contents of biomass.
Co-firing is practised where it can make power plants more effective for electric
utilities. This improved effectiveness may result from changes in policy considerations,
from environmental considerations, or from fuel supply considerations. For FORTUM,
the main arguments in favour of co-firing biomass and coal in their PC boilers are:

Pressure to reduce CO2 emissions in the existing coal-fired power plants!

Directives and measures of support for the use of biomass ! High taxation
of fossil fuels for energy production.

Possibility to reduce SO2 and NOx emissions.

A wider fuel array. The use of e.g. coals with higher sulfur contents than
normal is possible! savings in the coal costs.

The use of biomass in the existing PC boilers is much cheaper than building
new 100% biomass power-plants. Can also be cheaper and simpler than other
bio-PC processes (e.g. gasification).

Image questions. Possibility to produce energy from coal that is ‘‘light green’’.

These were the main driving forces for FORTUM to perform co-firing tests in one
of its own pulverised-coal units. The tests were conducted in April 1999 and March
and April 2000. The objective of the tests was to evaluate the impact of co-firing of
sawdust with coal on boiler performance, flame stability and emissions. Also the
effects on ash and gypsum were monitored. The tests were conducted without any
investments, and therefore the blending was done in the coal yard by a bulldozer,
and the coal/sawdust mixture was fed into the furnace through the coal mills.
As a result of the extensive combustion tests carried out at Naantali Power Plant,
new ideas about the co-firing concepts arose. Based on these new ideas, Fortum has
developed a new concept for the direct co-firing of different kind of biofuels. This
new concept is presented in Section 3.

2. Co-firing experiences at the Naantali power-plant

2.1. Description of the Naantali-3 power-plant

Naantali-3 is a tangentially-fired pulverised-coal CHP-unit (315 MWth, Sulzer

once-through boiler, steam 420 t/h, 180 bar, 535  C) that produces 79 MW elec-
tricity, 124 MW district heat and 70 MW steam (Fig. 1). The main fuel, coal, of the
power plant is pulverised in three mills (Loesche roller mills), and each feeds one
burner level, which consists of four burners.
 K. Savolainen / Applied Energy 74 (2003) 369–381 371

Fig. 1. Naantali power-station.

The boiler is equipped with 12 low-NOx-burners designed and manufactured by

FORTUM. The basic idea of the RI-JET (Rapid Ignition) low-NOx-burner is to
create a substoichiometric zone very close to the burner tip, and the two-stage
combustion is carried out by means of a single burner (Fig. 2). This single-burner
staging technique, combined with staging in the main vortex with OFA, is very

Fig. 2. Principles of the Fortum RI-JET burner.

372 K. Savolainen / Applied Energy 74 (2003) 369–381

effective in lowering the NOx-emissions, and it combines the advantages of swirl

stabilized burners and tangentially-stabilized combustion.
Flue gases of the boiler are led into the electrostatic precipitator, which collects
99.5% of the fly ash. Flue gases of units two and three are fed into the desulphuri-
zation plant.
The sulfur-dioxide content of flue gases is bound to the limestone slurry, the end
product being gypsum.
The ash formed at the power plant is delivered as a raw material to the concrete
industry. If the fly-ash quality is out of the specification (e.g. if the unburned carbon
content of the fly ash is > 5%), it will be utilized in landfills. Gypsum produced in
the desulphurization is sold to a gypsum-board factory, where it is used as a raw
material for building boards.

2.2. Fuel analysis

The biofuel used in the tests was pine sawdust, which was received from the saw-
mill, located about 50 km from the power plant. The sawdust was not screened
before it was mixed with coal: the particle size of the sawdust is presented in Fig. 3.

Fig. 3. The particle size of the sawdust.

 K. Savolainen / Applied Energy 74 (2003) 369–381 373

Table 1 presents the proximate and the ultimate analysis, and the lower heating values
of the sawdust, Polish coal and Russian Kuznetsk-coal. Table 2 presents the ash analysis
and the ash-fusion temperatures of the sawdust and coals used in the co-firing tests.

2.3. The blending method

The coal to Naantali is delivered by sea. The 13-m deep-water channel can be
used by ships carrying as much as 80,000 t of coal. The coal is unloaded into the

Table 1
Fuel analysis of biofuel and coals used in the co-firing tests

Parameter Sawdust PINE Russian coal Polish coal

Proximate analysis
Total moisture, wt.% (ar) 51–63 9–11 9–13
Volatile matter, wt.% (dry) 85–87 26–29 31–34
Ash, wt.% (dry) 0.25–0.3 9–11 12–15
FR-ratio (Fixed carbon/volatile matter) 6–7 2.1–2.2 1.7–1.8

Ultimate analysis (weight percentage dry basis)

C 51.5 76.5 70
H 6.2 4.5 4.2
O 41.8 4.9 9.2
N 0.2 1.9 1.2
S <0.1 0.3–0.4 0.8–1.0
Cl <0.01 0.25 0.21
Lower heating value (MJ/kg as received) 5.5–7 25–26 24–25

Table 2
The ash analysis and the ash-fusion temperatures of the sawdust and Polish coal used in the co-firing tests

Sawdust PINE Polish coal

Ash elemental analysis (weight percentage)

K2O 2–12 1.8–2.4
P2O2 4–8 0.6–0.7
CaO 22–62 2.5–3.6
MgO 6–16 1.3–2.6
Fe2O3 0.5–0.8 8.1
SO3 2–5 2.5–3.2
SiO2 1.5–5 50–55
Al2O3 1.1–2.5 22–25
TiO2 <0.6 0.9–1.3
Na2O 0.4–0.8 0.3–1.2

Ash-fusion temperatures  C (reducing atmosphere)

Initial deformation temperature (IT) 1495 1205
Softening temperature 1510 1240
Hemispherical temperature 1520 1275
Fluid temperature 1520 1340
374 K. Savolainen / Applied Energy 74 (2003) 369–381

7-hectare storage. This system has a capacity of 2200 t/h, and the storage can
hold over a million tones of coal. Coal is transferred from the coal yard to the
loading hopper by a bulldozer, and further to the power plant coal bins by belt
conveyors.
The wood waste used in the test burnings was transported to the power plant by
trucks, the capacity of which ranged between 40 and 120 m3 (about 13-40 tonnes
each). The space in the coal yard was limited, thus the sawdust was stockpiled just
outside the main coal yard. From there, the sawdust was transferred to the main
coal yard by a bucket charger with a capacity of about 10–12 m3 at a time.
Coal and wood were mixed by a bulldozer in the coal yard. According to the
analysis, the wood density was approximately one third that of the coal in the pile
and the blending ratios (by volume) were estimated based on these data. The coal
and the sawdust were spread in layers on top of each other by the bucket charger
and the bulldozer (Fig. 4). The thickness (and hence volumes) of the coal and the
layers of sawdust were based on the desired blending-ratio.
Because the blending of coal and sawdust were done in the coal yard, some fluc-
tuation in the blending ratio was expected.

2.4. Description of the tests

The co-firing tests at the Naantali Power Plant were carried out during March
1999 and March and April 2000, so that 3 months of continuous testing were con-
ducted. In the first year, preliminary tests were carried out. Injecting small propor-
tions of sawdust to the one mill started the initial tests. After that, small proportions
of sawdust mixed with Polish coal were tested in all the mills. The aim of the tests
executed in the first year was mainly to examine the effect of sawdust on the coal
mills, as well as to check the behaviour of the conveyors, hoppers and furnace, while
co-firing. Due to the positive results gained from the tests carried out in the spring of

Fig. 4. Blending of coal and sawdust in the coal yard.

 K. Savolainen / Applied Energy 74 (2003) 369–381 375

1999, the testing was continued in the spring 2000. The objectives of the second tests
were:

to mix the sawdust with two different coals: normal Polish coal and
unreactive Russian Kuznetsk-coal;

to test different proportions of sawdust and to find the maximum proportion
of sawdust, with which it was technically possible to co-fire at Naantali;

to check the effect of co-firing on the ESP (electrostatic precipitator) and
FGD (flue-gas desulfuration).

The duration of the second test period was two months and during that time the
sawdust was mixed with Polish coal and Russian Kuznetsk-coal. The three different
proportions of sawdust were tested during the second test-period: 25, 33 and 50
vol.%. In Table 3, the relationships between the proportion of sawdust in a volume,
mass and fuel-power percentages have been identified.
During the co-firing tests, the following process values were monitored:

Fuel behaviour on the coal conveyors, in the hoppers and coal mills

Combustion behaviour (ignition and flame stability with DIMACTM)

Slagging and fouling (process data and visual inspections)

Heat transfer in the furnace (process data and furnace exit temperatures)

Emissions (SO2, NOx and dust)

Burn-out (UBC in fly ash and quality of bottom ash)

Qualities of by-products.

2.5. Test results

2.5.1. Fuel behaviour on the coal conveyors and in the hoppers

The blending of coal and sawdust was carried out in the coal yard. The fuel blend
was then moved to the loading hopper by a bulldozer, and further to the power
plant coal bins by belt conveyors. The behaviour of the fuel blend in the hopper, on
the coal conveyors and in the power plant’s coal bins was normal. No self-ignition
or bridging over in the coal bins was noticed.

2.5.2. Fuel behaviour in the coal mills

The behaviour of the fuel blend in the coal mills was one of the major concerns,
when co-firing sawdust using this method (i.e. sawdust injection to the boiler

Table 3
The proportion of sawdust in coal–sawdust mixture in different units

The proportion of wood Blend 1 Blend 2 Blend 3

By fuel input (MWf%) 2.5 4.0 8

By mass (mass%) 9 14 25
By volume (vol.%) 25 33 50
376 K. Savolainen / Applied Energy 74 (2003) 369–381

through the existing mills). Therefore the mill performance was monitored carefully
during the tests. Specifically the power consumption of the mills, the grinding
results, and the mill outlet temperatures were monitored. Special attention was paid
to the general behaviour of the coal mills when introducing the highly-reactive fuel
(sawdust) to the coal mills.
The coal-mill performance was the limiting factor, when defining the maximum
proportion of co-fired sawdust. With high proportions of the sawdust ( > 33 vol.%),
the mill-drying capacity was inadequate and the capacity of the mills and the capa-
city of the whole boiler had to be limited. While co-firing 50 vol.-% of sawdust, the
boiler capacity was limited to 75% (320 t/h steam).
Pulverized coal and coal/sawdust (isokinetic) samples were taken from the coal
pipes. From these samples, the coal’s particle-size distribution was determined. The
mill fineness results for the baseline coal and the coal/sawdust blends (33 vol.%) are
presented in Table 4.
Grinding coal and wood waste in the roller mills had negative effects on the coal
fineness result: the amount of bigger particles was increased and the amount of smal-
ler particles reduced. Both had a negative effect on the burn-out efficiency of the coal.
Increased smoke formation in the coal mills was noticed during the co-firing tests.
This was probably due to wood sticks and chips, which came with the sawdust
(Fig. 5). The roller mills are not designed to handle fibrous materials like biomass.
The main function of a coal mill with regard to a biomass particle is drying before
feeding to the furnace. These bigger particles are not ground in the coal mill. They
are dried and flattened on the grinding table, and when they encounter the hot pri-
mary air in the reject box, they cause smoke formation and some times flames.

2.5.3. Ignition and flame stability

Ignition and flame stability were monitored with a DIMACTM flame-camera, and
visually through the inspection doors of the furnace. The DIMACTM flame-camera
monitors each flame individually. Cameras were set perpendicularly to the burners
in order to achieve the most informative view of the flames.
Ignition and flame stability were normal in all the test conditions. Even with high
proportions (50 vol.%) of sawdust, the ignition point was very near the burner throat
and the flame was stable. This was due to the use of modern low-NOx-burners, with
which the Naantali boiler No. 3 is equipped. The main feature of the RI-JET burners are
the stable flames, which are produced using a specially designed flame-stabilizing ring.

Table 4
The impact of co-firing on mill fineness (roller mills)

Particle size Polish coal Polish coal +33 vol.% S.D.

Mill 7 Mill 8 Mill 9 Mill 7 Mill 8 Mill 9

> 2 mm 0 0 0 0.2 0.2 0.7

> 0.6 mm 0.3 0.3 0.2 3.1 3.1 6.0
<150 mm 94 93 89 89 89 81
<75 mm 78 74 73 73 73 63
 K. Savolainen / Applied Energy 74 (2003) 369–381 377

Fig. 5. Sawdust composition.

2.5.4. NOx-emissions and unburned carbon in the fly ash

The nitrogen content of the sawdust is very low and the volatile-matter content
very high, which means that the NOx-emission should be low in the case of co-firing.
However, if the high moisture content of the sawdust causes the delayed ignition of
the coal flame, the overall NOx-emissions can be higher than with pure coal com-
bustion.
The burn-out efficiency of the coal has an influence on the boiler’s efficiency and
on the quality of the fly ash. The amount of unburned carbon mainly depends on the
fuel quality, mill operation, boiler design, and operating conditions. Grinding coal
and sawdust in the same coal-mill has a negative effect on the grinding result: the
amount of bigger particles was increased and the amount of smaller particles of coal
reduced. These phenomena have a bad effect on coal’s burn-out efficiency.
Because the content of the unburned carbon (UBC) in the fly ash is dependent on
the NOx-emission, the lower the NOx-emission, the higher the UBC. The results for
the NOx-emissions and UBC are presented in the same figure. In Fig. 5, the UBC is
presented as a function of NOx-emission, for the pure coal combustion of Polish
coal and pure combustion of Russian coal, as well as the co-firing of both fuels with
sawdust. In the Fig. 6, only the results from the boiler at 100% load are presented.
According to Fig. 5, with the same value of NOx-emission, the unburnt carbon in
the fly ash is higher, when co-firing coal with sawdust compared with only coal
combustion. When the sawdust proportion is small (25 vol.%), the effect is minor.
But when the sawdust proportion was increased to 33 vol.%, the amount of unburnt
carbon was increased by about 1%. This is mainly due to the worsened coal fineness,
when sawdust is injected to the boiler through the mills.
378 K. Savolainen / Applied Energy 74 (2003) 369–381

Fig. 6. Unburnt carbon in the fly ash versus NOx-emission.

2.5.5. Slagging and fouling

The slagging behaviour of the boiler was monitored visually and measured from
the process data (soot-blowing frequency, attemperation of water flows, etc.). During
the co-firing tests, the boiler slagging and fouling were at normal levels.

2.5.6. Heat transfer in the furnace

The steam temperature and flue-gas temperatures before and after the luvo were
monitored during the co-firing tests. All the process values were at the normal level
during the co-firing tests.

2.5.7. SO2 emissions and FGD performance

The qualities of the scrubber sludge remained stable during the experiments.
When sawdust and coal were co-fired, the chlorine content of the gypsum was
slightly lower than during the coal combustion. But when the changes in gypsum
composition were analyzed during the longer time scale of the power-plant’s normal
operation, the changes in the chlorine amount were found to be within normal var-
iations and not dependent on the fuel mixture.
The SO2-emissions were slightly higher in the coal combustion than in co-com-
bustion. That was due to the higher sulfur content of the coal than the wood. When
sawdust was mixed with the coal, the sulfur content of the fuel mixture was lower
 K. Savolainen / Applied Energy 74 (2003) 369–381 379

than the content in coal. The SO2-removal rate was 74% when only coal was burned
and 69% during the co-combustion of coal and sawdust. Also this slight variation in
the SO2-removal rate during the two experiments was a part of the normal variation
and not fuel-mixture dependent.

2.5.8. Dust emission and the ESP performance

During the co-firing tests, the voltage, current and efficiency of the first two stages
of ESP were measured. All these parameters stayed at the same level when co-firing
was compared with the situation while only coal was combusted. There were also no
differences in the U/I-curves measured during the tests. The voltage in the sawdust
combustion experiments was only slightly lower than the voltage in the coal com-
bustion at the same current. The breakdown voltages were at the same level after
both experiments. These experiments showed no significant changes in the ESP
performance during sawdust co-combustion.
The dust emissions after the ESP were lower during the co-combustion of coal and
sawdust than during the coal combustion. This is probably due to the low concen-
tration of ash in the sawdust.

2.6. Conclusion of the Naantali co-firing tests

The target of the co-firing tests made in the Naantali-3 unit was to determine
whether coal can be replaced by sawdust without any investment. The coal and
sawdust were mixed in the coal yard, and the blend was fed into the furnace via
existing coal mills. With this feeding method, the proportion of sawdust in the blend
during the tests varied between 25 and 50 vol.%, which corresponds to 9–25 mass%.
The co-firing tests carried out in Naantali-3 tangentially-fired unit were successful in
many ways. With co-firing, it was possible to reduce the CO2, SO2 and, in some
cases, NOx emissions. Also the co-firing had no negative effect on the boiler or
combustion performances, even with the high proportions of sawdust. Also the ESP
and FGD performances were unchanged.
The simultaneous feeding limits, however, changed the proportion of biofuels to
about 2.5% from the fuel power input (25 vol.%). If the proportion of the sawdust
is increased from that, the grinding of the coal will be worsened, resulting in a higher
amount of unburnt carbon in the fly ash. Also the drying capacity of the mills will
set the limit to the proportion of sawdust, that can be utilized. In the case of Naan-
tali, with high proportions of sawdust (> 4% from the fuel input and > 33 vol.%),
the mill drying capacity was not adequate and the capacity of the mills and boiler
had to be limited.
In addition, the array of biofuels suitable for simultaneous feeding is quite limited:
only the fuels with small particle size can be utilized. Very often, the price of these
biofuels is high and thus the benefits, which can be achieved with the simultaneous
feeding method, stay quite modest. This is the reason, why Fortum has concentrated
lately, on developing a new concept for co-firing. This new concept is flexible fuel:
thereby it is possible to increase the proportion of biofuel without disturbing the
coal grinding and burning processes.
380 K. Savolainen / Applied Energy 74 (2003) 369–381

3. Fortum’s new concept for direct co-firing

The following conclusions can be drawn from the extensive tests carried out at the
Naantali Power Plant:

It is possible to co-fire rather large amounts of biofuels in PC-boilers without

any influence on the boiler and combustion performance as well as the ESP
and FGD performances.

The limiting factors for co-firing, while injecting the biomass to the boiler
through the existing coal mills (i.e. simultaneous feeding), are the perfor-
mances of the mills; drying capacity and coal fineness.

Only sawdust or other biofuels with small particle sizes, can be utilized, when
applying simultaneous feeding of coal and biofuels.

A separate grinding and feeding system for biomass is needed. The most cost-
effective concept for co-firing of coal with biofuels in large PC boilers is based on the
separate grinding of the biomass with a simple crushing system and then burning it
using the special bio-burners or bio-coal-burners.
Co-firing a biofuel in existing pulverised-coal fired boilers sets high demands for
biofuel grinding technology. The critical factor is the particle size of the biofuel
which is necessary to ensure proper combustion efficiency and a stable flame.
According to the general opinion among researchers, the critical particle size is
approximately 1 mm. In order to achieve this target, not only a simple crushing
process, but also a complex and expensive micro-milling system are needed (see
Gelderland in Holland, Thermie Project No: SF/465/93/NL). The micronizing
process creates wood-dust particles that pose a possible hazard for dust explo-
sions and strict safety precautions must be taken, which further increases the
cost. However, according to our experience from full-scale co-firing tests, the
micronizing process will not be needed and the simple grinding system is sufficient
to produce a stable flame and achieve a high combustion-efficiency, provided
modern burners are used. With modern burner-technology, the particle size dis-
tribution of the biomass as large as 100% < 8 mm and 30–40% < 1 mm can be
accepted.
The experiences from Naantali Power Plant and a good knowledge of low-NOx
burning at Fortum was used when the new (patented) co-firing concept was devel-
oped (Fig. 7). In this process, the biomass (e.g. forest residue chips, bark, clean
demolition wood chips and agricultural wastes) is screened and ground in the
crusher process and the grinded biomass particles are fed to the boiler through
special bio-coal burners (RI-BIO). The mixing of biomass and coal can be carried
out in two different ways: (1) a ground biomass flow can be introduced to the
coal flow near the burner area, so that the coal and biomass are mixed before
they enter the furnace or (2) biomass can be fed to the furnace via a special
centre pipe so that biomass and coal particles are mixed in the flame. The dif-
ferences of these two mixing methods and their disadvantages and advantages in
every case are estimated using the computational fluid-dynamics (CFD) based
 K. Savolainen / Applied Energy 74 (2003) 369–381 381

Fig. 7. Fortum’s new co-firing concept for the direct co-firing of biofuel and coal.

modelling tool (Ardemus), so that the optimal combustion behaviour is always

employed.
With this new co-firing concept, it is possible to substitute 5–30% (from fuel
input) coal by renewable fuels.
This new system is being tested in a Finnish Power Plant during the autumn 2002.
Then, the target will be the substitution of the coal by 10% biomass for the fuel
input.